TSB: 04-007/06

2004-2006 MAZDA3 - FRONT BRAKE SQUEAK WHEN COLD

NOTE: This bulletin replaces 04-001/05. Please update your records accordingly.

BULLETIN NOTE

This bulletin supersedes the previous bulletin 04-001/05, issued 06/03/2005. The APPLICABLE MODEL(S)/VINS, REPAIR PROCEDURE, PART(S) INFORMATION, and WARRANTY INFORMATION have been revised.

APPLICABLE MODEL(S)/VINS

2004-2006 Mazda3

• 2.0L with VINs from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005)

• 2.3L vehicles with VINs lower than JM1BK****41 133301 (produced before December 17, 2003)

• 2.3L with VINs from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005)

DESCRIPTION

When applying the brakes during slow speed driving and in cold weather conditions, some vehicles may have a squeak noise coming from the front brakes. This may be caused by resonance in the pad, disc, and caliper.

A modified mounting support for the front brake calipers and modified pads have been introduced to correct this concern.

Customers having this concern should have their vehicle repaired using the following repair procedure.

REPAIR PROCEDURE

Peform the appropriate repair procedure as follows:

• 2.3L vehicles with VINs lower than JM1BK****41 133301 (produced before December 17, 2003) perform REPAIR PROCEDURE "A".

• 2.0L with VINs from JM1BK****41 100001 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "B".

• 2.3L with VINs from JM1BK****41 133302 to JM1BK****61 433115 (produced before September 19, 2005) perform REPAIR PROCEDURE "B".

REPAIR PROCEDURE "A"

1. Verify customer concern.

NOTE:

• If service bulletin 04-001/05 was already performed on this vehicle, the updated caliper mounting supports will already be installed. Verify that the updated supports are installed through visual inspection.

• If updated caliper mounting supports are not installed, continue with REPAIR PROCEDURE "A".

• If updated caliper mounting supports are installed, proceed to REPAIR PROCEDURE "B".

2. Replace front brake caliper mounting support assemblies and front pad & shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).

NOTE:

• Use new bolts 9975-60-230, two (2) per mounting support. The thread pitch is different than original. Do not reuse original mounting support and bolts.

3. Procede to REPAIR PROCEDURE "B".

REPAIR PROCEDURE "B"

1. Verify customer concern.

2. Replace front pad and shim set with the modified parts according to Workshop Manual (section 04-11 FRONT BRAKE (DISC) REMOVAL/INSTALLATION).

3. Verify repair.

PART(S) INFORMATION

NOTE:

• "XC" level mounting supports now require new flange bolts due to different thread pitch.

• "XA" level mounting supports are still okay to use if available in your dealer inventory. The XA level parts do NOT require new flange bolts.

WARRANTY INFORMATION

NOTE:

• This warranty information applies only to verified customer complaints on vehicles eligible for warranty repair. Refer to the SRT microfiche for warranty term information.

• Additional diagnostic time cannot be claimed for this repair.

• IMPORTANT: Warranty will NOT be paid if replacing caliper mounting supports unnecessarily. All 2.0L vehicles and 2.3L vehicles with VINs from JM1BK****41 133301 (Dec. 17, 2003 production) and above already have the modified caliper mounting supports installed from the factory.

• The modified brake pads have been installed at the factory starting with VIN JM1BK****61 433116 (September 19, 2005 production).

• This bulletin does not apply to vehicles after VIN JM1BK****61 433115 and warranty claims for this bulletin will not be accepted.